Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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DUAL-UNIT PAVING SYSTEM
FIELD OF THE INVENTION
The present invention relates generally to the field of paving units and
artificial stones or
flagstones for laying out pavements and is more particularly directed to such
stones giving the
resulting pavement a random and natural-looking appearance.
BACKGROUND OF THE INVENTION
Artificial covering units made of concrete are well-known to lay out pavements
or covering wall
surfaces on residential or commercial properties, for example defining the
surface of walkways
or patios. Such stones are advantageously relatively inexpensive to make, as
opposed to natural
carved flagstones, but the resulting pattern is often repetitive or has what
is called in this field an
unnatural "linear line effect". Great efforts have been made to design
artificial covering units
which provide a more natural look, while still retaining the ease in their
manufacture. It is worth
mentioning that the expressions "covering unit", "stone" and "flagstone" are
used throughout the
present description without distinction to define a unit used as a paving or
as a building material.
Attempts have been made in the past to develop sets of artificial stones
comprising stones of
different shapes used in combination with each other for paving a surface. The
natural random
look in those cases is obtained by combining artificial stones of different
shapes. However a
major drawback with those sets is that they often become a real puzzle for the
user to install and
combine the stones in a proper way. Another drawback is that currently
existing systems are
limited in terms of possible types of installation. Most systems allow
installation of the units
according to either one of the rotational or the linear tessellation
principle, but few offer the
possibility of installing the units by rotation or linearly (by "running bond"
or "stack bond").
There is currently a need in the market for larger artificial stones, since
they tend to provide a
more natural and esthetic look. Larger artificial stones also provide better
coverage per unit.
However, one drawback of larger stones is that they are also generally
heavier.
Known to the Applicant is US Patent 7,637,688, which describes a building unit
made of primary
elements which are rotational tessellation of one another. Since the building
units are all based
on a primary element, pavements created with such units tend to have a
discernible pattern.
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Also known to the Applicant is US design D602173. This design shows two units
which can be
paired to form a hexagonal shape. While the paired units allow the creation of
pavement with a
rotational tessellation, it does not allow assemble the units in a stack bond
or running bond
configurations.
Thus, there is presently a need for a paving system that provides a natural
random look, while at
the same time being easy to manufacture at a reasonable cost, and easy to
install for any
unskilled person in either one of linear and rotational tessellations.
SUMMARY OF THE INVENTION
Hence, in light of the aforementioned, there is a need for a paving system
including units for use
in combination with other units for covering a surface with a natural random
look, which by virtue
of their design and components, would be able to overcome some of the above-
discussed
concerns.
In accordance with the present invention, there is provided a dual-unit paving
system for
covering a surface. The system comprises pairs of first and second units. For
each pair, the first
unit has a lower face for facing the ground, an exposed upper face, and
sidewalls extending
from the lower face. The sidewalls of the first unit include a top side, a
bottom side, a left side
and a right side.
The second unit has a lower face for facing the ground, an exposed upper face
and sidewalls
extending from the lower face. The sidewalls of the second unit include a top
side, a bottom
side, a left side and a right side.
The bottom side of the first unit has a non-linear, irregular outline matingly
engageable with an
outline of the top side of the second unit for forming a hexagonal assembly.
The hexagonal
assembly formed by units A and B has six non-linear sides. This hexagonal
assembly allows to
form rotational tessellations.
The left side and the right side of the second unit have non-linear, irregular
outlines matingly
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engageable to at least respective portions of outlines of the right side and
left side of the first
unit.
The outline of the bottom side of the first unit comprises the outline of the
top side ofthe first unit
and the outline of the top side of the second unit comprises the outline of
the bottom side of the
second unit, for forming linear assemblies.
The first and second units forming the paving system can be installed either
by rotational
tessellation or by linear tessellation.
In one embodiment, the first and second units of a pair are created by
dividing a corresponding
hexagonal shape along an irregular separation line extending proximate the
first vertextowards
a location proximate the fourth vertex.
In one embodiment, the separation line delimiting the first and the second
units includes a
segment which is parallel and substantially similar to the outline of the side
extending between
the second and third vertices of the module. The separation line can be
obtained by performing
a linear transposition of the top segment of the first unit. The first unit
includes the second and
third vertices and a top side having an outline corresponding to the
separation line. The second
unit includes the fifth and sixth vertices and a bottom side having an outline
corresponding to the
separation line.
In one embodiment, for each paving module, the first side is concave and the
second side is
convex.
In one embodiment, the separation line extends from a location between the
first and sixth
vertex, closer to the first vertex, to a location between the fourth and fifth
vertex, closer to the
fourth vertex of an hexagonal assembly.
In one embodiment, each of the first and second units of a paving module
comprises a top and
a bottom side, and second unit being shaped such that when laid over the first
unit, the top and
bottom sides of the second unit coincide with the top and bottom sides of the
first unit.
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In one embodiment, the first and second units are provided with respective top
faces, said top
faces including at least two patterns of a flagstone, the patterns of the
first unit differing from the
patterns of the second unit. Preferably, the patterns are delimited by deep
joints.
In one embodiment, the dual-unit paving system includes at least two groups of
two first units
and two second units, as defined above. In this paving system, the top face of
the first unit
differs from the top face of the first unit. Similarly, the top face of the
second unit differs from the
top face of the second unit. The paving system thereby allows the creation of
four or more
different paving modules, each module having a distinct top face.
In one embodiment, the paving system includes several groups of paired
modules. The first and
second units of the paving system can be installed linearly, by alternating
the first and second
modules.
The paving system according to the invention can advantageously be used for
creating patio,
pathways, sidewalks or stepping stones.
The present invention is also very advantageous for the manufacturer. The
first and second unit
of the paving system can be placed either one facing the other or side by
side, thus optimizing
the clamping operation during the manufacturing process.
Advantageously, the paving units can be assembled and installed either by
rotational
tessellation or by linear tessellation, with little or no "linear effect".
Advantageously, with a paving
system including two groups of first and second units as defined above, twelve
different module
configurations can be created when the units are installed according to the
rotational tessellation
principle. By using two different units matable with one another into a paving
module, a multitude
of different designs can be created, either by rotational or linear
tessalation, in stack or running
bond configurations.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages and features of the present invention will become
more apparent
upon reading the following non-restrictive description of preferred
embodiments thereof, given
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for the purpose of exemplification only, with reference to the accompanying
drawings in which:
Figure 1 is a perspective view of a dual-unit paving system, according to an
embodiment.
Figure 2A is a top plan view of the first unit of the paving system of Figure
1. Figure 2B is a top
plan view of the second unit of the paving system of Figure 1.
5 Figure 3 is a schematic top view of the first and second units of the
dual-unit paving system of
Figure 1, facing one another and forming a hexagonal assembly, according to an
embodiment.
Figure 3A is a top view of the outline of the bottom side of the first unit or
of the outline of the top
side of the second unit, according to an embodiment of the invention.
Figure 4A is a schematic top view of the first and second units, placed side
by side in first linear
assembly. Figure 4B is schematic top view of the first and second units,
placed side by side in a
second linear assembly.
Figure 5 is a perspective view of unit B being placed over unit A. Figure 5A
is a top view of unit
A placed over unit B.
Figures 6A and 6B are schematic representations of the outer outline of the
hexagonal
assembly shown in Figure 3.
Figure 7A is a top view of two groups of pairs of units, according to an
embodiment. Figure 7B is
a top view of two groups of pairs of unit, according to another embodiment.
Figure 8 is a top view of different configurations of hexagonal assemblies,
according to an
embodiment of the invention.
Figure 9 is a top view of twelve different configurations of hexagonal
assemblies.
Figure 10A are top views of another pavement made of different hexagonal
assemblies placed
in different orientations and shown assembled according to an embodiment of
the invention.
Figure 10B is a top view of a pavement made from different hexagonal
assemblies having the
same orientation and shown assembled according to an embodiment of the
invention.
Figure 11 to 14 are top views of pavements made of first and second units
assembled in
different linear assemblies, according to different embodiments of the
invention. Figures 12 and
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13 show a pavement according to a stack bond configuration. Figure 14 show a
pavement
according to a running bond configuration.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the following description, similar features in the drawings have been given
similar reference
numerals. In order to preserve clarity, certain elements may not be identified
in some figures if
they are already identified in a previous figure.
It will be appreciated that positional descriptions such as "lower", "upper",
"vertical", "horizontal",
"top", "bottom", "side" and the like should, unless otherwise indicated, be
taken in the context of
the figures and should not be considered limiting or as implying a required
orientation during
use.
The dual-unit paving system advantageously allows the creation of different
assemblies,
according to linear or rotational tessellations. With only two different
shapes of units, the system
can provide the illusion of having been assembled randomly and created from
natural
flagstones. The present paving system also provides units which are as large
as possible while
remaining easy to install in different configurations. By "tessellation" it is
meant a covering, tiling
or paving of one or more shapes to cover a surface, without any substantial
gaps between
shapes.
Referring to Figure 1, a first unit A and a second unit B are shown. They form
a pair of units A, B
of a dual-unit paving system 8, for covering a surface. The first unit A has a
lower face 20 for
facing the ground, an exposed upper face 21, and sidewalls extending from the
lower face 20.
The second unit B also has a lower face 23 for facing the ground, an exposed
upper face 25 and
sidewalls extending from the lower face 23.
Preferably, the upper exposed face 21, 25 of at least one of the first and
second units A, B
includes two or more different patterns 78i to 78iv and 80i, 80ii, which are
preferably flagstone
patterns. The patterns are preferably all different, so as to increase the
randomness aspect of
pavements created with the dual-unit paving system. The flagstones patterns
are preferably
delimited by deep joints 82.
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Figure 2A is a top view of unit A. The sidewalls of unit A include a top side
12, a bottom side 14,
a left side 16 and a right side 18. The terms "top", "bottom", "left" and
"right" refer here to the
orientation of the sides of unit as shown in Figure 2, which also corresponds
to the orientation of
the sides when looking at the unit over its upper, exposed face, such as when
the unit is placed
on the ground and one is looking at the unit directly over it. The terms
"top", "bottom", "right" and
"left" are used to facilitate and simplify reference to the different sides of
the unit, and they could
be referred as "first", "second", "third" and "fourth" sides as well.
The outline of each side 12, 14, 16, 18 is made of several segments at angle
from one another.
The outline of the sides is non-linear and irregular. By "irregular" it is
meant that the sides
include several segments and split deviations.Toward the lower face of the
unit, the sides are
made of several flat surfaces. The junction of the upper exposed face 21 of
the unit with the
sides is chiselled, so as to imitate natural carved stone.
Figure 2B is a top view of unit B. The sidewalls of unit B also include a top
side 22, a bottom
side 24, a left side 26 and a left side 28. The outline of each side is made
of several angled
segments. Similar to unit A, each side of unit B is made of several
intersecting flat surfaces
toward the lower face of the unit B and the junction of the sides with the
upper exposed face 25
of the unit is chiselled. The different patterns can be colored and given a
texture to imitate
natural flagstones.
Referring to Figures 2A and 2B, and also to Figure 3, the bottom side 14 of
the first unit A has a
non-linear, irregular outline matingly engageable with the outline of the top
side 22 of the second
unit B. By "matingly engageable", it is meant that the units can be assembled
or paired, so that
sides will closely fit one another. When units A and B are assembled so as to
face one another,
as shown in Figure 3, they form a hexagonal assembly 10 having six, non-linear
sides. By
"hexagonal" it is meant that the shape is reminiscent of a hexagon. The
hexagonal assembly
has an hexagon-based shape, with six sides and six angles.
Still referring to Figure 3, in this particular embodiment of the second unit
B, the outline of the
top side 22 includes a portion which corresponds to a vertical translation of
the outline of the
bottom side 24. This feature is also present in unit A, for which the outline
of the bottom side 14
includes a portion which corresponds to a vertical translation of the outline
of the top side 12. It
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will also be appreciated that preferably, the outline of the top side 12 of
the first unit A and
adjacent segments 16i, 18i of the left and right sides 16, 18 correspond to a
vertical translation
of the outline of the bottom side 14 of the first unit A. By "vertical"
translation it is meant that the
translation is made substantially perpendicularly relative to the sides.
Still referring to Figure 3 and also to Figure 3A, the respective outlines of
the top side 22 of the
second unit B and of the bottom side 14 of the first unit A are preferably
similar, and are referred
to as a separation outline 52.
In this particular embodiment, the separation outline 52 includes two outer
portions 54, 58 and
one inner portion 56. This portion 56 has an outline similar to the bottom
side 24 of the second
unit B. Preferably, at least one of the outer and inner portions are formed by
several non-linear
segments, such as for portions 54 or 56 of the separation line. Still
preferably, the separation
line has two summits 60, 62 and a valley 64 between the two summits 60, 62. In
this
embodiment, summit 60 has a first segment and a second segments 66, 68
extending from it,
the first segment 66 being a rotational image of the second segment 68.
Similarly, summit 62
has first and second segments 70, 72 being rotational images of one another.
Still referring to Figure 3, it is preferable that the units A and B have
approximately the same
height h. This height h is measured on unit A from the highest point on side
12 to the highest
point of side 14. Similarly, the height h of unit B is measured from the
highest point on side 22 to
the highest point of side 24. Of course, the term "highest" is to be taken in
the context of the
Figures, and relates to a vertical or "Y" axis.
Referring to Figure 3 and 3A, as can be appreciated, the first and second
units A and B are
formed by dividing the hexagonal shape 10 in two different and distinct units
A and B. The
separation line 52 used for forming the units A, B is located approximately
halfway between the
highest point and the lowest point of the hexagonal assembly 10. The
separation line 52
includes within its profile a portion of the perimeter of the hexagonal
outline, transposed or
translated linearly along a central axis of the assembly 10. It will also be
noted that the inner
portion 56 of the separation line 52 includes the outline of the sides of the
hexagonal shape 10.
The remaining portions 54, 58 of the separation line 52 also correspond to
other sections of the
outline of the hexagonal shape.
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Referring to Figures 4A and 4B, two different linear assemblies 11 are shown.
As can be
appreciated, the left side 26 and the right side 28 of the second unit B have
non-linear, irregular
outlines matingly engageable to at least respective portions 50, 48 of the
outlines of the right
side 18 and left side 16 of the first unit A. For example, such linear
assemblies 11 can be used
to form pathways. In this case, the linear assemblies are oriented
horizontally
Referring to Figures 4A, the outline of the bottom side 14 of the first unit A
includes the outline of
the top side 12 of the first unit A and the outline of the top side 22 of the
second unit B includes
the outline of the bottom side 24 of the second unit B. This allows the units
to form linear
assemblies along a vertical orientation as well. Units A can be stacked
vertically, in a stack bond
configuration, and so can units B.
In addition, the top side 12 of the first unit A is preferably substantially
similar to the bottom side
of 24 of the second unit B, so that hexagonal assemblies can be stacked
vertically, such as
shown in Figure 10B.
Referring to Figures Sand 5A, the second unit B is shaped such that when laid
overthe first unit
A, the top and bottom sides 22, 24 of the second unit B coincide with the top
and bottom sides
12,14 of the first unit A. In other words, when the second paving unit B is
placed over the first
paving unit A, it fits perfectly within the outline of the first unit A. Both
top and bottom sides of
units A and B coincide with one another. Unit B is smaller in size than unit
A. In other words, the
top surface of unit B is smaller than the top surface of unit A. The volume
and weight of unit B
are also smaller than the volume and weight of unit A.
Referring now to Figures 6A and 6B, different aspects of the hexagonal
assembly 10 formed by
units A and B are shown. The outline of the hexagonal assembly 10 formed by
units A and B
has six sides 36, 38, 40, 42, 44 and 46. They form three pairs of sides 30, 32
and 34. The
hexagonal assembly 10 has first 1, second 2, third 3, fourth 4, fifth Sand
sixth 6 consecutive
vertices, and the separation outline 52 preferably extends from near the first
vertex1 to nearthe
fourth vertex 4. It will be also noted that each of the sides of the hexagonal
assembly 10 is
formed by several segments at angle from one another, and the outline of a
side does not
include any repetitive portion or segment. This feature allows creating
pavements with a more
random, irregular aspect.
1
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Adjacent sides of the hexagonal assembly preferably spaced apart by an angle
of approximately
120 , and the six sides 36, 38, 40, 42, 44 and 46 are preferably congruent. By
"congruent", it is
meant that the sides are superposable, so as to be coincident throughout.
5 When the first and second units A, B are facing one another to form the
hexagonal assembly 10,
two adjacent sides of the hexagonal assembly preferably comprise a convex side
36, 40, 44 and
a concave side 38, 42, 46. This characteristic allows the assemblies to
interlock with one
another when forming a pavement by rotational tessellation of such assemblies,
and thus results
in a more stable installation.
Referring now to Figures 7A and 7B, pairs of units Al ¨ Bl; A2 ¨ B2; Al' ¨ B1'
and A2' ¨ B2' are
preferably divided into first 84, 84'and second 86, 86' groups. In Figure 7A,
the upper faces 74 of
the first unit Al differs from the upper face 88 of the first unit A2.
Similarly, the upper face 76 of
the second unit B1 differs from the upper face 90 of the second unit B2. Of
course, in other
embodiments of the invention, the dual-unit paving system can include three or
more groups of
different pairs of units A, B. The number of different possible combinations
PC is obtained by
multiplying the number of first paving units (type A) by the number of second
paving units (type
B); and NbA x NbB = PC. Preferably, the surface area of the flagstone patterns
of unit A is
substantially similar to the surface area of either one of the exposed face of
second unit B, or of
one of the patterns of unit B.
Advantageously, the specific shape given to the units facilitates the
"clamping" of the units,
during the manufacturing of the units. During the manufacturing process, after
unmolding and
curing the units and prior to packaging them, the units must be clamped with
large clamps and
placed over pallets for wrapping. The specific configuration of the first and
second units A and B
allows to assemble them such that the space occupied by the units on the
pallets is maximized,
thus facilitating their handling.
As shown in Figure 8, this characteristic of the dual-unit paving system
allows creating four
different hexagonal assemblies 10i, 10ii, 10iii, 10iv. Each assembly has a
distinct upper face
appearance.
1
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Referring to Figure 9, the four hexagonal assemblies 10i, 10ii, 10iii and 10iv
can be positioned
according to three different angles of rotation: 00, 120 and 240 . The dual-
unit system thereby
allows the creation of twelve different configurations of hexagonal
assemblies.
As shown in Figure 10A, a pavement 92 obtained by a rotational tessellation of
different
hexagonal assemblies obtained with units Al, Bl, A2 and B2 has a random
aspect, without any
repeating pattern. The rotational tessellation is obtained by tessellating
several paired units A
and B in different rotational orientations. In addition, the deep joints of
the units A and B are
located on their respective top faces so as to "break" the linear effect when
the units are rotated.
As shown in Figure 10A, the combination of a rotational installation of the
units, with the
appropriate positioning of the deep joints, results in a more random and
natural installation than
the one presented in Figure 10B. It is also more difficult to distinguish a
linear pattern.
Of course, it is also possible to create a pavement 92' without rotating the
units, and by
assembling units A and B from the same or from different groups, as in Figure
10B.
Referring to Figures 11 to 14, other possible pavements formed by a linear
tessellation of
several pairs of first and second units A, B are shown. In these examples, the
first and second
units A, B of a pair are placed side by side. Figure 11 is an example of a
horizontally aligned
tessellation.
As shown in Figures 12 and 13, different pavements 94, 94' and 94" are made
using a stack
bond configuration. The pavements include at least two rows, where the first
units Al or A2 of
the first row face the respective first units A2 or Al of the second row.
Similarly, units B1 or B2
are facing units B2 or Bl. Figure 13 is an example a vertically aligned
tessellation.
In Figure 14, the pavement 96 is made using a running bond configuration. A
running bond
pavement includes at least two rows (in this particular case, three rows are
used) where the first
units Al or A2 of the first row face the respective second units B1 or B2 of
the second row.
As can be appreciated, the paving units of the present system allow creating,
when combined,
large paving modules or assemblies, having a random and natural look. Such
large paving
assemblies yet remain easy to install, since they are subdivided into smaller
sub-units A and B,
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and since the modules have a substantially similar outline. In addition, a
single worker is
generally able to lift and install the paving units. The result of combining
the first and second
paving units is larger looking stones having a random look which enables to
loose the linear and
hexagonal shape present in existing products. In addition, the specific
perimeter or outline of
each paving unit advantageously facilitates their clamping during the
manufacturing process and
allows maximization of the space occupied by the units on the pallets.
The scope of the claims should not be limited by the preferred embodiments set
forth in the
examples, but should be given the broadest interpretation consistent with the
description as
a whole.
